Section | RoboteQ AX1500, AX2550 manual

	Revision History	3
SECTION 1	Important Safety Warnings			13
	This product is intended for use with rechargeable batteries 13
	Avoid Shorts when Mounting Board against Chassis 13
	Do not Connect to a RC Radio with a Battery Attached						13
	Beware of Motor Runaway in Improperly Closed Loop						13
SECTION 2	AX1500
	Quick Start 15
	What you will need		15
	Locating the Connectors			15
	Connecting to the Batteries and Motors 17
	Connecting to the 15-pin Connector 18
	Connecting the R/C Radio			19
	Powering On the Controller 20
	Default Controller Configuration				20
	Connecting the controller to your PC using Roborun					21
	Obtaining the Controller’s Software Revision Number					22
	Exploring further	22
SECTION 3	AX1500 Motor Controller Overview				23
	Product Description		23
	Technical features		24
SECTION 4	Connecting Power and Motors to the Controller 27
	Power Connections		27
	Controller Power	28

Controller Powering Schemes 30

Powering the Controller from a single Battery 30

Powering the Controller Using a Main and Backup Battery 31

Connecting the Motors 32

Single Channel Operation 33

Converting the AX1500 to Single Channel 33

Power Fuses 34
Wire Length Limits 34
Electrical Noise Reduction Techniques		35
Power Regeneration Considerations		35
Overvoltage Protection	36
Undervoltage Protection	36

Using the Controller with a Power Supply 36

AX1500 Motor Controller User’s Manual

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RoboteQ AX1500, AX2550 user manual Section

Contents

Dual Channel Digital Motor Controller AX1500 AX1500 Motor Controller User’s Manual Date Version Changes Revision HistoryRevision History AX1500 Motor Controller User’s Manual Section Section Section 100 122 144 173 AX1500 Motor Controller User’s Manual Beware of Motor Runaway in Improperly Closed Loop Important SafetyDo not Connect to a RC Radio with a Battery Attached Important Safety Warnings AX1500 Locating the ConnectorsQuick Start What you will need AX1500 Controller Rear View AX1500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Signal Pin RC Mode RS232 Mode Analog Mode Connecting to the 15-pin Connector Connecting the R/C Radio Connecting the R/C Radio Parameter Default Values Letter Powering On the ControllerDefault Controller Configuration Connecting the controller to your PC using Roborun Connecting the controller to your PC using Roborun Exploring further Obtaining the Controller’s Software Revision Number Product Description AX1500 Motor Controller Overview Technical features Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder Inputs optional Compact Open Frame PCB Design Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller Power Mended Off Configuration Controller Power Powering the Controller from a single Battery Controller Powering Schemes Controller Powering Schemes Powering the Controller Using a Main and Backup Battery Powering the AX1500 with a Main and Backup Supply Connecting the Motors Converting the AX1500 to Single Channel Single Channel Operation Wire Length Limits Power Fuses Electrical Noise Reduction Techniques Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Undervoltage Protection Using the Controller with a Power SupplyOvervoltage Protection Using the Controller with a Power Supply Connecting Power and Motors to the Controller General Operation Input Command ModesBasic Operation Basic Operation Open Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General Operation Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control Temperature Max Amps User Selected Current Limit SettingsTemperature-Based Current Limitation Motor Current = Battery Current / PWM ratio Battery Current vs. Motor CurrentBattery Current vs. Motor Current Off Regeneration Current Limiting Programmable Acceleration Programmable Acceleration Command Control Curves Exponentiation Parameter Value Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Stop using External SwitchInverted Operation Activating Brake Release or Separate Motor Excitation Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital Inputs AX1500 Connections Connecting Sensors and Actuators to Input/OutputsAX1500 Connections AX1500’s Inputs and Outputs Connecting Sensors and Actuators to Input/Outputs AX1500’s Inputs and Outputs Signal Type Use Activated List and Pin Assignment Pin1 Connecting devices to Output C Connecting devices to Output C Connecting Switches or Devices to Input F Connecting Switches or Devices to Input E Connecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert Input Analog Inputs Connecting Position Potentiometers to Analog Inputs Ana Ana2 Operating Mode Pin Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Operating Mode Ana 1 p11 Ana2 p10 Ana 3 p12 Ana 4 p8 Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhm Using the Analog Inputs to Monitor External Voltages Internal Voltage Monitoring Sensors Connecting User Devices to Analog InputsInternal Heatsink Temperature Sensors Temperature Conversion C Source Code Internal Heatsink Temperature Sensors Connecting Sensors and Actuators to Input/Outputs Optical Incremental Encoders Overview Installing Connecting Using Encoder ModuleOptical Incremental Encoders Overview Recommended Encoder Types Installing, Connecting and Using the Encoder Mod Pulse Frequency in Hz = RPM / 60 * PPR Installing the Encoder ModuleInstalling the Encoder Module Connecting the Encoder Pin Name Cable Color Cable Length and Noise ConsiderationsCable Length and Noise Considerations Motor Encoder Polarity Matching Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Optional Limit Switches SW1 SW2 GND Effect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 Fwd Motor 1 Rev Motor Fwd Motor Rev Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Using the Encoder to Track Position Using the Encoder to Track Position Distance = Destination Counter value / Divider RS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC Utility Encoder Testing and Setting Using the PC Utility Installing, Connecting and Using the Encoder Mod Mode Description Closed Loop Position ModeSelecting the Position Mode Mode Description Sensor Mounting Closed Loop Position ModePosition Sensor Selection Feedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Pot wiring for RS232 or RC Command and Analog Feedback Feedback Potentiometer wiring in Analog Mode Analog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Sensor and Motor Polarity Using Optical Encoders in Position Mode Encoder Error Detection and Protection Encoder Error Detection and ProtectionAdding Safety Limit Switches SW1 SW2 Control Loop Description Using Current Limiting as ProtectionUsing Current Limiting as Protection PID tuning in Position Mode PID tuning in Position Mode Closed Loop Position Mode Selecting the Speed Mode Closed Loop Speed Mode Tachometer or Encoder Mounting Tachometer wiringClosed Loop Speed Mode Speed Sensor and Motor Polarity Speed Sensor and Motor Polarity Adjust Offset and Max Speed PID tuning in Speed Mode PID tuning in Speed Mode Closed Loop Speed Mode Power On LED Normal Fault Condition LED MessagesDiagnostic LED Power On LED Normal and Fault Condition LED Messages Output Off / Fault Condition C Operation C radio control mode Connector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin Input or Number Output Signal Description Operation Input Circuit Description Input Circuit DescriptionSupplied Cable Description RC Cable wiring diagram Powering the Radio from the controller Wiring for powering R/C radio from controller Powering the Radio from the controller Operating the Controller in R/C mode Connecting to a Separately Powered Radio Reception Watchdog Reception Watchdog Joystick Deadband Programming Transmitter/Receiver Quality Considerations Effect of deadband on joystick position vs. motor speed Command Control Curves Joystick Calibration Left/Right Tuning AdjustmentActivating the Accessory Outputs Data Logging in R/C Mode Data Logging in R/C Mode 112 Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog ModePin Input or Number Signal Output Description Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer = U/R = 5V / 1000 Ohms = 0.005A = 5mA Selecting the Potentiometer Value Analog Deadband Adjustment Analog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety Modified Analog cable with RS232 output data logging for PC Data Logging in Analog Mode 120 Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 Mode Extending the RS232 Cable Cable configurationCable configuration Establishing Manual Communication with a PC Communication SettingsBits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Roboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog mode Commands Acknowledge and Error Messages RS-232 Watchdog Controller Commands and QueriesCommand Type Description Controller Commands and Queries Set Motor Command ValueSet Accessory Output Syntax Query Power Applied to MotorsQuery Amps from Battery to each Motor Channel Query Battery Voltages Query Heatsink TemperaturesQuery Analog Inputs ?r or ?R Query Digital Inputs Reset Controller Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameter Location Description Active after Flash Configuration Parameters List Motor Control Mode Input Control ModeAddress Access Read/Write Effective After Reset Value Mode See pages Bit Definition See pages Amps Limit Acceleration Input Switches Function Exponentiation on Channel 1 and Channel Address Channel Access Read/Write Effective InstantlyRC Joystick or Analog Deadband Default Encoder Time Base 1 Left/Right Adjust Joystick Min, Max and Center Values Default Encoder Distance DividerDefault PID Gains Location Function Reading & Changing Operating Parameters at Runtime Read/Change PID Values Operating Modes RegistersBit Function Address 82 P1 83 I1 84 D1 85 P2 Controller Status Register PWM Frequency Register Bit Model or Function Controller Identification RegisterCurrent Amps Limit Registers Read Encoder Counter RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers Or !Q n Read Speed Read Speed/Distance Read Encoder Limit Switch StatusRead Distance DD= parameter value Switch ValueRead / Modify Encoder Module Registers and Parameters Address Parameter Description Size Access Register Description Switch StatusEncoder Hardware ID code Speed or Distance 1 or Counter 1 Counter Read/Write MailboxDestination Register 1 Register Description Speed 1 Distance 1Time Base 1 Encoder Threshold Decimal Bit Hex Controller Output Counter Read Data FormatCounter Read Data Format 154 Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode Data Logging Cables Analog and R/C Modes Data Logging String Format Dec Hex Decimal to Hexadecimal Conversion TableDecimal to Hexadecimal Conversion Table UDec Hex AX1500 Motor Controller User’s Manual 159 160 System Requirements Using the Roborun Configuration UtilityDownloading and Installing the Utility Using the Roborun Configuration Utility Connecting the Controller to the PC Roborun Frame, Tab and Menu Descriptions Parameter Selection and Setting and Special FunctionsRoborun Frame, Tab and Menu Descriptions View Controller Connector Pinout File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller Parameters Motor Control Mode Control SettingsInput Command Adjustment Loading, Changing Controller Parameters Power Settings Joystick Timing Analog or R/C Specific SettingsDeadband Closed Loop Parameters Encoder Setting and Testing Encoder Setting and Testing Encoder Module Parameters Setting Viewing Encoder Data Running the MotorsExercising the Motors Running the Motors Motor Power settingRun/Stop Button Measurement Transmit and Receive Data Real-Time Strip Chart RecorderInput Status and Output Setting Logging Data to Disk Connecting a Joystick Using the Console Command Entry Using the ConsoleTerminal Screen Keep Watchdog Alive Using the Roborun Configuration Utility Send Reset String Operating the AX1500 over a Wired or Wireless LANViewing and Logging Data in Analog and R/C Modes Loading and Saving Profiles to Disk Roboserver screenshot when idle Operating the AX1500 over a Wired or Wireless LAN Updating the Encoder Software Updating the Controller’s Software Creating Customized Object Files Objectmaker creates controller firmware with custom defaults 180 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Thermal Considerations Mechanical SpecificationsMounting Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions Wire DimensionsWeight 186